Extra comfortable shoe soles using elastomeric nonwovens and nanotechnology

Overview

This solution introduces extra comfortable shoe liners and sole materials produced from melt-processed thermoplastic elastomer (TPE) nonwovens reinforced with nanoparticles. Conventional cushioning materials used in athletic footwear, such as EVA, PU, and TPU foams, air cushioning systems, gels, and composites, often lack sustainability and thermal comfort. The proposed approach combines thermoformable porous fiber webs with nanoparticle additives to deliver improved cushioning, energy absorption, resiliency, breathability, and moisture management in a single molded structure. The technology targets athletic footwear applications where impact absorption, comfort, and thermal regulation are critical performance factors.

Technical specifications

• Material platform: Melt-processed thermoplastic elastomer nonwovens produced by spunbonding or meltblowing in a single step
• Nanoparticle reinforcement: Nanoclay, graphite, C60, POSS, and inorganic disulfide nanotubes applied via dip coating, ultrasonic spray coating, or melt blowing with compounded polymer-nanoparticle blends
• Composite structure: Sandwiched panel constructions of nanoparticle-reinforced webs molded into shaped products
• Performance attributes: Shock absorption and energy dissipation at high strain rates, compressibility and recovery, moisture transport, heat transfer, breathability, and mechanical durability
• Thermal comfort: Enhanced through conductive nanoparticle additives that improve thermal conductivity, ventilation, insulation, and moisture management
• Processing advantage: Thermoformable webs enable molding into complex shoe liner and sole geometries

Technology readiness level

The underlying nanoparticle-reinforced elastomer technology has been validated through prior research and is protected by a recently issued patent on energy absorbing nanocomposite materials. Laboratory studies using DMA and high-frequency testing on sandwiched composites have demonstrated the ability to tune energy absorption and dissipation at high strain rates through material selection and processing. The proposed next phase involves extruding TPE nonwovens with affordable conductive nanoparticle master batches, molding them into sandwich panels, and systematically evaluating compressibility, recovery, moisture transport, heat transfer, breathability, and mechanical performance across varying layer configurations. Initial development will use commercially available resins, with bio-based and fully biodegradable alternatives anticipated as they become available.